Mounting system

ABSTRACT

The present invention provides apparatus and methods for mounting pipes or other elongate structures to a mounting surface.

FIELD OF THE INVENTION

This invention relates generally to mounting systems and in particularto apparatus and methods for mounting pipes, conduit, and other tubularstructures on a surface.

BACKGROUND

Generally, building utility services require mounting of apparatus suchas pipes in areas not easily accessed. In particular, utility servicesrequire wall and rooftop mounting of plumbing, heating, ventilating, airconditioning and electrical related pipes, conduit and cables. Mountingapparatus must be tailored to various considerations such as the weightof the pipes or other utilities support, as well as the wall or roofingconditions. For example, changes in weather conditions dictate that amounting system placed on a roof be able to accommodate the expansionand contraction of pipes fastened thereto. In addition, the mountingapparatus must be resilient enough to handle the stresses of acommercial environment and still remain reliable. Mounting systems,which do not provide a secure and adequate surface area, will damage theroof, and potentially cause leakage and further damage to the interiorof the building.

Various systems and apparatus have been developed to address thesesystems, however, each has its drawbacks. For example, wood stanchionsare subject to deterioration in environments of rain and snow.Similarly, steel will also corrode with rust. In addition, roof topsconstitute precarious working conditions, and transporting heavymounting apparatus back and forth from a ground level to elevatedworking locations is not only additional work, but can also constitute asafety hazard.

What is needed therefore is a system and apparatus that provides stablemounting, is resistant to adverse conditions and is also easilytransportable to elevated working locations.

SUMMARY

The present invention provides improved apparatus and methods formounting pipes, conduits, cables and the like to a surface, such as arooftop. The present invention provides for motion of the mountedstructures to accommodate expansion and contraction of pipes or conduitmounted thereto and also protects the roof or other mounting surfacefrom damage. The mounting system additionally provides flexibility inmounting structures so that a number of mounts and mounting positionsare available, especially for the mounting of more than one pipe orother elongated structures. Apparatus of the present inventionadditionally provides for e flexibility in mounting structures onslightly irregular surfaces and is durable and resilient to the weatherelements. Other features include a mounting system and apparatus that isrelatively low cost and provides easy mobility to an installation site,such as a rooftop.

It is within the scope of the present invention to mount a variety oftubular structure, including, but not limited to, plumbing, electricalconduit, air conditioning pipe and ductwork, and venting ductwork.

Some embodiments of the present invention can include a steel channelstrut fastened to a polyvinyl chloride base with approximate dimensionsof 10 inches long by 4 inches wide by 4 inches high. Generally the basewill include a triangular shape to add stability and minimize unecessary material. It is understood by those skilled in the art that adescription of any one particular embodiment is not intended in anexclusive or limiting sense. Various embodiments encompassing differentsizes and types of base and channel are within the scope of the presentinvention. Accordingly, the embodiments described herein are intended todemonstrate a pipe mounting system according to the present invention,with the understanding that other embodiments within the scope andspirit of the present invention are possible.

Various features and embodiments are further described in the followingfigures, drawings and claims.

DESCRIPTION OF THE DRAWINGS

The accompanying drawings are shown by way of illustration of specificembodiments in which the inventions may be practiced. These embodimentsare described in sufficient detail to enable those skilled in the art topractice various embodiments of the invention, and it is to beunderstood that other embodiments may be utilized and that modificationto the embodiments described herein may be made without departing fromthe spirit and scope of the present invention. The following descriptionof the drawings and the detailed description are, therefore, not to betaken in a limiting sense, and the scope of the present invention ismore fully described by the claims below and equivalents thereof.

FIG. 1 illustrates a perspective view of some embodiments of the presentinvention.

FIG. 2 illustrates a block diagram of some embodiments of the presentinvention comprising a supplemental power source

FIG. 3 illustrates some embodiments of the present invention whichinclude an inline Stirling type apparatus.

FIG. 4 illustrates some embodiments of the present invention whichinclude an electrical generator which charges batteries used to powerthe thermoelectric devices.

FIG. 5 illustrates a base portion with two or more elongate strutsattached.

FIG. 6 illustrates some embodiments of a clamp.

FIG. 7A-7B illustrates some embodiments with a generally triangular baseportion and a mounting plate.

DETAILED DESCRIPTION

Overview

The present invention provides a lightweight and rugged means ofmounting a variety of elongated structure, including, but not limitedto, plumbing, electrical conduit, tubing, air conditioning pipe andductwork, venting ductwork or other elongated structures on a rooftop ofother mounting surface. In addition, some embodiments provide aprotective surface plate to shield a mounting surface from damageresulting from movement of pipes or other elongate structures.

Referring now FIG. 1, a perspective view of a mounting system 100according to some embodiments of the present invention is illustrated.The mounting system 100 can include a base portion 101 which providesmechanical support for an elongate strut portion 102. Generally, thebase portion 101 comprises a rigid, semi-rigid or flexible material,such as plastic or aluminum. The rigid, semi-rigid or flexible materialis formed into a first surface 108 which can be placed upon a mountingsurface (not illustrated), sidewalls 107, end walls 106 and a topsurface 109. The sidewalls 106 support the elongate strut portion 102,as can the end walls 106. In addition, in some preferred embodiments,the end walls 106 seal the sidewalls base and top surface therebyforming a sealed in hollow area within the base portion 101.

An elongate strut portion 102 can be fixedly attached to the top surface109 of the base 101, the elongate strut portion 102 being suitable forfastening a pipe or other elongate structure to the mounting system 100.In some preferred embodiments, the elongate strut portion 102 includes achannel formed by a first side wall, a second side wall, and a back wall9 illustrated and described below at FIG. 5, integrated such that anopening is formed between the first side wall and the second side wall,the first side wall including a first flange having a first recess andthe second side wall including a second flange having a second recess,the first flange and the second flange define an opening in the channelfor mating with a clamp which secures the pipe.

In some preferred embodiments, the base portion 101 can be formed frompolyvinyl chloride (PVC), which can be formulated as a flexible,semi-rigid or rigid material that is chemically nonreactive. As used inthe present invention, rigid PVC can be one or more of: machined, heatformed, welded, and solvent cemented. PVC can be machined using standardmetal working tools and finished to close tolerances and finisheswithout great difficulty. For the purposes of this document, a rigidmaterial can be a material with less than 10% give, a semi-rigidmaterial can include a 10% to 20% amount of give and a flexible materialcan include a material which provides greater than 20% of give.

In some embodiments, PVC base portions can be colored, such as with asafety related color; colored coded to indicate a type of pipe or cablemounted thereto; labeled with an indication of a type of pipe or cablemounted thereto; or otherwise marked. PVC embodiments and other plasticembodiments can generally accept paint and also perform well under mostsilk screening processes. It is also within the scope of the presentinvention to include base portion 101 materials with molded-in color.Some preferred embodiments can include plastics which are relativelyunaffected by water, alkalis, nonoxidising acids, hypochloritesolutions, and aliphatic hydrocarbons.

PVC resins can also be mixed with other additives such as impactmodifiers and stabilizers, providing hundreds of PVC based materialswith a variety of engineering properties. There are three broadclassifications generally recognized in the art for rigid PVC compounds:Type I, Type II, and CPVC. Type II varies from Type I PC due to greaterimpact values, but lower chemical resistance. CPVC has greater hightemperature resistance. In some embodiments, CPVC materials areconsidered “unplasticized”, because they can be less flexible than theplasticized formulations.

Rigid PVC can include, for example, a hard, amber-colored material.Precise properties can depend on formulation. Plasticised PVC can bemade flexible, for example, by selection of type and proportion of aplasticizer, which are well known in the arts. As used herein, the termflexible can include materials that are resistant to changes in shape,but may under pressure be deformed and return to an original shape whenthe pressure is removed.

Generally, and without limitation, other examples of base portion 101material which can be used in various embodiments, can include: nylon, athermo set plastic such as bakelite; chlorine-free plastics such aspolyethylene and polypropylene; polyisobutylene; polystyrene; highimpact polystyrene; thermoplastic polyurethane or polycarbonate;engineering plastics, including, but not limited to: acrylic, nylon andacetal. Some embodiments can also include a tough, shatter-resistant;fire-resistant; and corrosion resistant plastic such as ABSPoly(Acrylonitrile, Butadiene, Styrene) hereinafter ABS; high impactpolystyrene and high impact polypropylene.

Some preferred embodiments can also include ABS polymers which can beengineered to give a range of physical properties, depending on theratio of the monomeric constituents and the molecular levelconnectivity. Typically, a styrene-acrylonitrile glassy phase can betoughened by an amorphous butadiene/butadiene-acrylonitrile rubberphase; high heat ABS, impact modified ABS, antistatic ABS, and alloyswith other plastics such as polycarbonate, polyurethane, and PVC

In some embodiments, the mounting system 100 can include one or moresecuring surfaces 103 with a securing hole 104 through the securingsurface 103 and at east a portion of the base portion 101. A centerlinethrough the mounting hole intersects the mounting surface (notillustrated).

Some embodiments can also include a transport hook 105 which can beinterconnected with other transport hooks 105 to secure one mountingsystem 100 to another mounting system 100 during transport of themounting systems 100, such as, for example, while transporting themounting systems onto a roof for installation.

In some preferred embodiments, the elongate strut portion 102 is moldedin a single unit with the base portion 101. Those schooled in the artwill understand that advanced injection molding techniques allow for theelongate strut portion 102 and the base portion 101 to be formed in asingle injection molding process from the same or different materials.Accordingly, in some embodiments, for example, the base portion 101material may include a flexible material and the elongate strut portion102 may be formed of a rigid material. In other embodiments the elongatestrut portion 102 may include any rigid material, including, but notlimited to, steel and plastic. Elongate strut 102 composition anddimensions may differ without departing from the scope and spirit of thepresent invention. The elongate strut 102 may be finished or rustproofed using paint or any other finishing or rust proofing method,including, but not limited to, galvanization, anodization, hot dipping,and electroplating. Some embodiments may also optionally includemodifications such as perforations or reinforcement ribs.

Referring now to FIG. 2, an end or profile view illustrates the end wall106 of the base portion 101. As illustrated in FIG. 2, the end wall 106includes an essentially triangular shape. The triangular shape isparticularly well suited to those embodiments with a single elongatestrut portion 102, however, other embodiments with two or more elongatedstrut portions 102 are also within the scope of the invention and arefurther discussed below. The base portion 101 can include the firstsurface 108 which can be placed upon a mounting surface, and sidewalls107 which join the first surface 108 with a top surface 109. By way ofnon-limiting example, some preferred embodiments can include a topsurface 108 that is approximately 1.5 inches wide and a first surface108 which is approximately 4 inches wide (not necessarily drawn toscale). In addition, some exemplary embodiments can include a topsurface 109 which is approximately 4 inches higher than the firstsurface 108.

At FIG. 2A, a top down view further illustrates the base portion 101including the mounting holes 104 and the elongate strut portion 102.

Referring now to FIG. 3A, a hook 301 or other clip like fastening devicecan be utilized in some embodiments to join two or more mounting systems101. For example, and referring now to FIG. 3B, in some embodiments, thebase portions 101 can be fashioned to include a recessed potion in thefirst surface 108 which allows the mounting systems 100 to be stackedand joined by the hooks 301. Joined mounting systems can facilitatetransport of two or more mounting systems, such as transport up onto aroof environment. In other embodiments, the mounting systems can bejoined by the hook 301 with two first surfaces facing each other asillustrated in FIG. 3C.

The embodiment illustrated in FIG. 3C can be advantageous since itprovides for a fastening means between two mounting systems, each withan essentially flat first surface 108. In some embodiments, a flat firstsurface 108 can be advantageous since it allows for the first surface108 to sit flush against a mounting surface. The two flush surfacesprevent mice, rats or other rodents, as well as bees or insects fromcreating a nest or other refuge place under the mounting 100. In thismanner the rigid, semi-rigid or flexible material from which the presentinvention is formed further distinguishes over some embodiments in theprior art, since wood, foam an d other pliable materials are ofteneasily gnawed to form refuge for undesirable inhabitants under themounts previously known.

Referring now to FIG. 4, in another aspect which distinguishes over theprior known mounting systems, the present invention can include ahooking portion 105 which allows for the mounting system 100 to beattached to a line 401 for transport. The lines can be particularlyuseful for transporting the mounting systems 100 onto an elevatedinstallation environment, such as a roof top or scaffolding, since aworker can establish themself firmly upon the elevated work environmentand pull the mounting systems 100 up the line instead of having to carrythe mounting systems 100, which can be precarious and thereforedangerous. In addition, the relatively lightweight of a hollow PVCplastic mounting system further provides advantages over relativelyheavy wood, metal or pliable foam embodiments.

Referring now to FIG. 5, some additional embodiments are illustratedwhich incorporate multiple elongate strut portions 502. As illustrated,in order to better accommodate the multiple elongate strut portions 502,the base portion 101 can be formed into a square or rectangular shape501. As illustrated in FIG. 5, two or more elongate strut portions 502can be attached to the top surface 503 or integrally formed of the samematerial as the top surface 503 and positioned essentially parallel toeach other, or be positioned at an angel to each other, according to theneeds of a particular mounting application. Embodiments can include eachstrut 102 having a same size channel. In other embodiments, one or morechannels can be of different sizes for accommodating different sizedclamps on a single base portion.

Referring now to FIG. 6, one example of a clamp which can be used inimplementing the present invention is illustrated. According to thepresent invention, a clamp 601 can include any device which can secure apipe, cable or other elongate structure to the elongate strut portion102, 502. Accordingly, a clamp 601 can refer to one or more of a varietyof clamps, including, but not limited to, pipe clamps, cable clamps,electrical fittings, saddles, brackets, spring bolts, beam clamps,roller clamps. Some embodiments can also include clamps 601incorporating thermal isolation or shock isolation for piping or clampswhich limit corrosion or abrasion of the piping by the clamp. In someembodiments, a clamp 601 can also include a bolt whereby the bolt headis inserted into the channel with the threaded portion exposed and a nutand plate or strap are used to compress the pipe against the uppersurfaces of the flanges of the strut. Embodiments can also includeclamps with fingers which are received or captured in a recess forpositively securing the clamping devices to the channel or strut. Theclamps described herein are not intended to be exclusive or limiting,and other mounting structures exist which are clamps and which are notmentioned specifically herein. Such mounting structures are within thescope and spirit of the present invention.

FIG. 6 illustrates some embodiments of a clamp 601. The clamp 601 caninclude an engagement fingers 602 which engage the elongate strutportion 102, 502. The engagement fingers 602 can mate with a firstflange 504 and first recess 505 of the elongate strut portion and thesecond flange 506 and second recess 507 of the elongate strut portion502. The clamp 601 can also include a fastener hole 603 through which afastener, such as a threaded bolt, a rivet, or any other device knowndevice that is suitable can be used to join a clamp 601 around a pipe.

FIG. 7A-7B illustrate still additional aspects of the present inventionwhich include the relative light weight of the mounting systems 100, 500according to the present invention, and the ability of the presentinvention to protect against damage to the integrity of the roofmaterial. Expansion and contraction of pipes, cables and other elongatestructures which may be mounted to the mounting systems of the presentinvention 100, 500, may cause the base portions 101, 501 to move backand forth. Constant movement may wear on the roofing material andeventually create leaks. In order to prevent such wear, some embodimentsof the present invention can include a surface plate 700 which is placedunder the base portion 101, 501. Embodiments which include a surfaceplate 700 can also provide additional protection to a mounting surface,such as a rooftop. Wherein utilization of the surface plate 700 reducesthe chance of penetrating the roof membrane due to movement of themounting device. The mounting system 100 of the present invention alsoprovides resilience to the various weather extremes, both in itsconstruction, and in its ability to accommodate motion on the part ofthe mounted structures due to expansion, contraction, vibration, wind,or other motion.

Accordingly, in some embodiments, the plate 700 can include anengagement lip 705 which can overlap an edge 701 extending from the baseportion 101, 501. The engagement lip 705 can facilitate keeping the baseportion 101, 501 positioned over the plate 700 and yet provide enoughleeway that the base portion 101, 501 can move freely as a result ofpipe expansion and contraction without causing the plate 700 to move.The surface plate 700 can thereby provide a mount for elongatestructures, such as pipes with degrees of freedom for motion in everydirection thereby allowing the pipes to compress or stretchlongitudinally and compress or expand in lateral motion withoutunintentional perforations to a roofing membrane.

In some embodiments, the base 700 can also include mounting holes 703which can allow the plate 700 to be fastened to the mounting surfacewith fasteners, such as, for example threaded bolts, screws or rivets.In some embodiments, such as the ones illustrated in FIG. 7A-7B, themounting holes can be counter sunk to allow for free movement of thebase portion 101, 501 over the plate 700.

Although the base portion 101, 501 of the present invention hasspecifically been designed to be lightweight in order to facilitate easeof transport, in some embodiments, it may be desirable to provide a baseportion of sufficient mass to provide stability against shifting underthe pipes or other elongate structure. Accordingly, the presentinvention provides for some embodiments with a removable seal 704 whichprovides for access to the interior of the hollow base portion sealed bythe end walls 106. After the mounting system 100 has been transportedto, or proximate to an installation site, the removable seal 704 can beremoved and a material may be injected into the base portion 101, 501 inorder to increase the mass of the base portion. The increased mass willprovide stability and resist movement of the base portion. The materialwhich can be inserted into the base portion 101 can vary according to aparticular application. For example, some embodiments may includepouring sand or water or some other ubiquitous material into the baseportion 101, 501 to increase the mass of the base portion 101, 501 afterthe base portion 101-501 has been placed in position to mount pipes, oreven following the installation of the pipes. Other materials mayinclude cement or an aqueous solution with an antifreeze additive. Itshould be noted that filling a base portion 101, 501 with a cement orother setting material can also be beneficial to deterring rodents frominhabiting the base portions 101, 501.

Although the present invention has been demonstrated as a roof mountingsystem 100, the mounting system 100 may be employed in a variety ofmounting applications, including internal mounting, wall mounting orattic mounting. The mounting system 100 may be used for a number ofdifferent plumbing, electrical, and duct mounting applications.Furthermore, the dimensions of the base may differ without departingfrom the scope and spirit of the present invention. Also the types ofclamps used and the dimensions of the channel may vary for differentapplications. The base 101 may be constructed of any plastic materialwhich has a sufficient modulus to support the weight of the pipe mountedto it with adequate stability and is sufficiently weather resistant fora particular application.

Although a number of embodiments of the present invention have beendescribed, nevertheless, it will be understood that variousmodifications may be made without departing from the spirit and scope ofthe invention. For example, some embodiments can also include two ormore struts are mounted at angles to each other to accommodate mountingelongate structures at angles to one another. The base dimensions andshapes may be varied to accommodate the geometries of the struts and theweights of the elongate structures mounted thereto. Other variations andembodiments are possible without departing from the present invention.Several combinations of clamps and positions are contemplated by severalembodiments of the present invention and are within the scope and spiritof the present invention and various methods or equipment may be used toimplement the steps described herein. In addition, various labelingschemes, coloring, safety markings, casings and packaging can also beincluded in order to better adapt a mounting system to a particularenvironment of a specific application. Accordingly, other embodimentsare within the scope of the following claims.

1. A mounting system for fastening an elongate structure to a mountingsurface; the mounting system comprising: a base portion comprising: afirst surface to be placed on the mounting surface; sidewalls to supporta top surface; and end walls to seal the sidewalls base and top surfacethereby forming a hollow area within the base portion; and an elongatestrut portion fixedly attached to the top surface of the base, theelongate strut portion comprising a channel for mating with a clamp, thechannel comprising a first side wall, a second side wall, and a backwall, integrated such that an opening is formed between the first sidewall and the second side wall, the first side wall including a firstflange having a first recess and the second side wall including a secondflange having a second recess, the first flange and the second flangedefining the opening.
 2. The mounting system of claim 1 additionallycomprising: a clamp for fastening an elongate structure to the elongatestrut portion, the clamp including at least two fingers, a first fingerwhich mates with the first flange and first recess and a second fingerwhich mates the second flange and second recess.
 3. The mounting systemof claim 2 wherein the elongate strut portion is embedded within thebase portion such that the opening is exposed to receive the clamp. 4.The mounting system of claim 1 wherein the base portion comprises arigid or flexible plastic.
 5. The mounting system of claim 4 wherein thebase portion comprises polyvinyl chloride.
 6. The mounting system ofclaim 1 additionally comprising at least one securing surface and asecuring hole therethrough, a centerline through the securing holeintersecting the mounting surface.
 7. The mounting system of claim 1wherein the elongate strut portion comprises a rigid plastic and iscontiguously formed with the base portion.
 8. The mounting system ofclaim 5, wherein the elongate structure comprises a pipe.
 9. Themounting system of claim 2, wherein the clamp comprises a pipe clamp.10. The mounting system of claim 5 wherein the base portion and theelongate strut portion comprise a contiguous plastic unit.
 11. Themounting system of claim 1 additionally comprising a transport hook forconnecting multiple mounting systems to each other.
 12. The mountingsystem of claim 1 additionally comprising a transport hole though thebase and a transport mechanism attached to the transport hole andconnecting multiple mounting systems for transport.
 13. The mountingsystem of claim 12 wherein the transport mechanism comprises a flexibleline.
 14. The mounting system of claim 1 wherein the first surfacecomprises a width and a length and the top surface comprises a width anda length and the width of the top surface is less than the width of thebase portion.
 15. A method for attaching an elongate structure to amounting surface, the method comprising the steps of: positioning a baseproximate to the mounting surface, wherein the mounting apparatuscomprises: a first surface to be placed on the mounting surface;sidewalls to support a top surface; and end walls to seal the sidewallsbase and top surface thereby forming a hollow area within the baseportion; securing a clamp within an elongate strut portion fixedlyattached to the top surface of the base, the elongate strut portioncomprising a channel for mating with a clamp, the channel comprising afirst side wall, a second side wall, and a back wall, integrated suchthat an opening is formed between the first side wall and the secondside wall, the first side wall including a first flange having a firstrecess and the second side wall including a second flange having asecond recess, the first flange and the second flange defining theopening; and clamping the elongate structure with the clamp within thechannel.
 16. The method of claim 15 additionally comprising the step ofmating fingers of the clamp within the channel.
 17. The method of claim16 additionally comprising the step of securing the base portion with afastener through a securing hole formed in a securing surface formed inthe base.
 18. The method of claim 15 wherein the base comprises rigidpolyvinyl chloride.
 19. A method of transporting multiple mountingsystems for fastening an elongate structure to a mounting surface; themethod comprising: securing the multiple mounting systems to each otherwith a hook fashioned into the a base portion of the mounting system,the base portion additionally comprising: a first surface to be placedon a mounting surface; sidewalls to support a top surface; and end wallsto seal the sidewalls base and top surface thereby forming a hollow areawithin the base portion; and an elongate strut portion fixedly attachedto the top surface of the base, the elongate strut portion comprising achannel for mating with a clamp, the channel comprising a first sidewall, a second side wall, and a back wall, integrated such that anopening is formed between the first side wall and the second side wall,the first side wall including a first flange having a first recess andthe second side wall including a second flange having a second recess,the first flange and the second flange defining the opening; andfastening the multiple mounting systems to a flexible line, saidflexible line having a portion for acting as a handgrip used to carrythe multiple mounting systems.
 20. The method of claim 19 additionallycomprising the step of hoisting the multiple mounting systems in avertical direction to a height at least equivalent to a single story ofa building.